1996 CHRYSLER VOYAGER Service Manual

SPECIAL TOOLS
41TE AUTOMATIC TRANSAXLE
Puller C-637
Pressure Gauge (Low) C-3292
Pressure Gauge (High) C-3293SP
Dial Indicator C-3339
Oil Pump Puller C-3752
Seal Puller C-3981B
Universal Handle C-4171
Seal Installer C-4193A
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 159

Adapter C-4996
Remover Kit L-4406
Gear Puller L-4407A
Bearing Installer L-4410
Gear Checking Plate L-4432
Bearing Puller L-4435
Differential Tool L-4436A
Special Jaw Set L-4518
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SPECIAL TOOLS (Continued)

Installer L-4520
Thrust Button L-4539-2
Bearing Splitter P-334
Puller Set 5048
Remover/Installer 5049-A
Installer 5050A
Installer 5052
Compressor 5058A
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SPECIAL TOOLS (Continued)

Compressor 5059-A
Installer 5067
Pliers 6051
Installer 6052
Installer 6053
Button 6055
Plate 6056
Disk 6057
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SPECIAL TOOLS (Continued)

Installer 6061
Remover 6062-A
Holder 6259
Bolt 6260
Installer 6261
Tip 6268
Remover/Installer 6301
Remover/Installer 6302
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SPECIAL TOOLS (Continued)

Installer 6536-A
Cooler Flusher 6906A
Puller 7794-A
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SPECIAL TOOLS (Continued)

POWER TRANSFER UNIT
INDEX
page page
GENERAL INFORMATION
POWER TRANSFER UNIT................ 165
DIAGNOSIS AND TESTING
FLUID LEAK DIAGNOSIS................. 167
SEAL IDENTIFICATION................... 165
REMOVAL AND INSTALLATION
DIFFERENTIAL CARRIER SEAL............ 170
END COVER BALL BEARING.............. 178
END COVER SEAL...................... 169
HALF SHAFT INNER SEAL................ 175
INPUT SHAFT COVER SEAL.............. 174
INPUT SHAFT END SEAL................. 177INPUT SHAFT SEAL..................... 169
OUTER HALF SHAFT SEAL............... 177
POWER TRANSFER UNIT (P.T.U.).......... 167
POWER TRANSFER UNIT OUTPUT SEAL.... 171
REAR COVER O-RING................... 171
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION........ 180
SPECIFICATIONS
TORQUE............................. 180
SPECIAL TOOLS
SDP POWER TRANSFER UNIT............ 181
GENERAL INFORMATION
POWER TRANSFER UNIT
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located. The Transfer Unit provides the power to the
rear wheels through a hypoid ring gear and pinion
set.
The Power Transfer Unit is sealed from the tran-
saxle and has its own oil sump. The Unit uses SAE
85W-90 gear lubricant and holds 1.15 liters (1.22
quarts).
The Power Transfer Unit fill plug is located on the
end cover (Fig. 1).Do not mistake the black plas-
tic inspection plug located on the P.T.U. case
for the fill plug.Service of the Power Transfer Unit is limited to:
²Seals
²Gaskets
²One ball bearing
²Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION
For accurate seal diagnosis, repair seal name and
location is critical. Refer to (Fig. 2), (Fig. 3), (Fig. 4)
and (Fig. 5) for correct seal name and location.
Fig. 1 Fill Plug LocationFig. 2 Seal Location
NSTRANSAXLE AND POWER TRANSFER UNIT 21 - 165

Power Transfer Unit Components
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DIAGNOSIS AND TESTING (Continued)